Automation equipment control system

ABSTRACT

A automation equipment control system comprises a general purpose computer with a general purpose operating system in electronic communication with a real-time computer subsystem. The general purpose computer includes a program execution module to selectively start and stop processing of a program of equipment instructions and to generate a plurality of move commands. The real-time computer subsystem includes a move command data buffer for storing the plurality of move commands, a move module linked to the data buffer for sequentially processing the moves and calculating a required position for a mechanical joint. The real-time computer subsystem also includes a dynamic control algorithm in software communication with the move module to repeatedly calculate a required actuator activation signal from a joint position feedback signal.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is a continuation-in-part of U.S. Ser. No.09/750,433, filed on Dec. 28, 2000, now U.S. Pat. No. 6,442,451.

FIELD OF THE INVENTION

[0002] This invention relates to an apparatus and method for controllingautomation equipment and more particularly, to a versatile controlsystem suitable for controlling automation equipment of variouselectromechanical configurations.

COPYRIGHT NOTIFICATION

[0003] Portions of this patent application contain materials that aresubject to copyright protection. The copyright owner has no objection tothe facsimile reproduction by anyone of the patent document, or thepatent disclosure, as it appears in the Patent and Trademark Office.

BACKGROUND OF THE INVENTION

[0004] Industrial robots and similar highly flexible machine toolsgained commercial acceptance during the late 1970s. Since then, the useof industrial robots has increased substantially, particularly forautomobile manufacturing.

[0005] The guiding purpose for industrial robots is manufacturingflexibility. Robots allow assembly lines and work cells to makedifferent articles with no or minimal manual equipment changes. The listof robot applications in manufacturing is long and ever increasing.Examples include computer vision inspection, spot and arc welding, spraypainting, drilling, part placement, and adhesive application.

[0006] The boundary between robots and machine tools is not strictlydefined, however. Compared with conventional machine tools, robotsgenerally have more joints (or axes) of motion thereby offering moredegrees of freedom for positioning an end effector. In the roboticsfield, the term “end effector” has been adopted to cover the variety ofactive equipment carried by robots. Such equipment varies according tothe manufacturing application, e.g. spot welding.

[0007] Robots generally include positioning arms with mechanical joints,actuators such as motors for causing movement about the joints, andsensors which aid in determining the position (or pose) of the robot.Although most include these core components, industrial robots new andold otherwise vary greatly in their electromechanical configurations.

[0008] For example, some robots rely only on revolute, (i.e. rotary)joints, while some are equipped with combinations of linear and revoluteaxes. Robots with a series of extending arms and revolute joints havebeen labeled articulating robots.

[0009] Even among a given class of robots there is mechanical variation.The revolute joints of articulating robots may be, for example, offsetfrom their supporting arm—a shoulder joint, centered to the supportingarm—an elbow joint or axially aligned with the supporting arm—a wristjoint. Likewise, linear joints may be co-linear or orthogonal. Actuatorsand feedback sensors are another source of the varying configurations.For example, some robots are equipped with stepper motors, others servomotors.

[0010] Electronic control systems are employed to control and programthe actions of robots. For the necessary coordinated action between theend effector and the robot positioning, robot control systems preferablyprovide a level of software programming as well as an interface to fieldI/O and end effector subsystems. Conventional robot control systems arecollections of customized electronics that vary according to robotconfiguration and robot manufacturer.

[0011] In manufacturing processes, robots are directed by a list ofcontrol instructions to move their respective end effectors through aseries of points in the robot workspace. The sequences (or programs) ofrobot instructions are preferably maintained in a non-volatile storagesystem (e.g. a computer file on magnetic-disk).

[0012] Manufacturing companies, the robot users, through their engineersand technicians, have come to demand two important features frommanufacturing control systems. First, robot users seek control systemsimplemented using commercially available standard computers andoperating systems rather than customized proprietary systems. This trendtoward the use of standard computer hardware and software has beenlabeled the “open systems movement.”

[0013] Control systems based on standard computers are preferred becausethey offer robot users simplified access to manufacturing data viastandard networks and I/O devices (e.g. standard floppy drives), theability to run other software, and a competitive marketplace forreplacement and expansion parts. Underlying the open systems movement isthe goal of reducing robot users' long-term reliance on machine tool androbot manufacturers for system changes and maintenance.

[0014] A second feature sought by robot users is a common operator andprogrammer interface for all robots, facility (if not company) wide. Acommon user interface for all robots reduces the need for specializedoperator training on how to use the customized proprietary systems.

[0015] With respect to the open-systems feature, efforts at delivering arobot control system based on standard, general purpose computer systemshave not been fully successful because of the limitations of generalpurpose operating systems. Robot safety and accuracy requirementsdictate that robot control systems be highly reliable, i.e. crashresistant, and tied to real-time. The multi-feature design objectivesfor general purpose operating systems such as Microsoft Windows NT® haveyielded very complex, somewhat unreliable software platforms. Moreover,such systems cannot guarantee execution of control loops in real-time.

[0016] With respect to the common operator interface features, attemptsto offer even limited standards to operator interfaces have not extendedbeyond a specific robot manufacturer. Notwithstanding the difficulty ingetting different robot manufacturers to cooperate, the wide variety ofelectromechanical configurations has heretofore substantially blockedthe development of robot control systems with a common operatorinterface.

[0017] Accordingly, it would be desirable to provide an improved robotcontrol system that both employs standard computer systems andaccommodates robots of different configurations. Specifically, it wouldbe desirable to provide the advantages of open systems and a commonoperator interface to robot control.

SUMMARY OF THE INVENTION

[0018] Robot control systems of the present invention provide robotcontrol via commercially standard, general purpose computer hardware andsoftware. The control systems and methods according to the presentinvention are usable with robots of varying electromechanicalconfigurations, thereby allowing a common operator interface for robotsfrom different robot manufacturers.

[0019] The present invention provides a control system for running orprocessing a program of robot instructions for robots equipped with amechanical joint, a mechanical actuator to move the joint and a positionfeedback sensor. The robot mechanical actuators receive an activationsignal and the feedback sensor provides a position signal.

[0020] A control system embodying the present invention includes ageneral purpose computer with a general purpose operating system and areal-time computer subsystem in electronic communication with thegeneral purpose computer and operably linked to the mechanical actuatorand the position feedback sensor. The general purpose computer includesa program execution module to selectively start and stop processing ofthe program of robot instructions and to generate a plurality of robotmove commands.

[0021] Within the real-time computer subsystem is a move command databuffer for storing a plurality of move commands. The real-time computersubsystem also includes a robot move module and a control algorithm. Themove module is linked to the data buffer to sequentially process themove commands and calculate a required position for the mechanicaljoint. The control algorithm is in software communication with the robotmove module to repeatedly calculate a required activation signal fromthe feedback signal and the required position for the mechanical joint.

[0022] Another aspect of the present invention provides a robot controlsystem suitable for controlling robots of different electromechanicalconfigurations. The control system includes a robot-independent computerunit in electronic and software communications with a robot-specificcontroller unit.

[0023] The robot-independent computer unit is operably linked to therobot by an I/O interface and includes a video display and a firstdigital processor running an operator interface module for creating asequence of robot move commands. The robot-specific controller unitincludes a second digital processor running a real-time tied operatingsystem and a robot move module for executing the robot move commands.

[0024] The operator interface module preferably includes a configurationvariable for storing data defining the electromechanical configurationof the robot, a first code segment for generating a first operatordisplay according to a first electromechanical configuration, a secondcode segment for generating a second operator display according to asecond electromechanical configuration, and a third code segment forselecting the first or second code segment according to theelectromechanical configuration.

[0025] Control systems according to the present invention are wellsuited for use with various types of automation equipment havingactuator-driven mechanical joints. The automation equipment categoryincludes, but is not limited to, robots, machine tools, laboratoryliquid-handling systems, computer media handling systems, therapeuticsystems, surgical systems, and the like.

[0026] In this aspect, the present invention provides a control systemfor processing a program of instructions for automation equipment havinga mechanical joint, a mechanical actuator to move the joint and aposition feedback sensor. The mechanical actuator is set up to receivean activation signal and the feedback sensor is set up to provide anindication of the joint's position. The equipment control systemcomprises a general purpose computer with a general purpose operatingsystem and a real-time computer subsystem operably linked to themechanical actuator and the position feedback sensor. The real-timecomputer subsystem is in electronic communication with the generalpurpose computer, preferably via a standard data bus.

[0027] The general purpose computer includes a program execution moduleto selectively start and stop processing of the program of instructionsfor the automation equipment and to generate a plurality ofcorresponding move commands. The real-time computer subsystem has a movecommand data buffer for storing the plurality of move commands, a movemodule linked to the data buffer to sequentially process the pluralityof move commands and calculate a required position for the mechanicaljoint of the automation equipment.

[0028] Yet another aspect of the present invention is the capability tosimultaneously control multiple such automation devices. According tothis aspect, the present invention provides a control system suitablefor controlling a plurality of automation devices with mechanical jointsand mechanical actuators to move the respective joints. The controlsystem comprising a general purpose computer with a general purposeoperating system and a plurality of real-time computer subsystems eachin electronic communication with the general purpose computer.

[0029] The general purpose computer includes a video display and a firstdigital processor adapted to run an operator interface, which serves tocreate a sequence of device move commands. Each real-time computersubsystem is operably linked to one of the automation devices. Eachsubsystem has a digital processor adapted to run a real-time tiedoperating system and a move module for executing the move commands.

[0030] Other advantages and features of this invention will be readilyapparent from the following detailed description of the preferredembodiment of the invention, the drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In the accompanying drawings that form part of the specification,and in which like numerals are employed to designate like partsthroughout the same,

[0032]FIG. 1 is schematic block diagram illustrating the softwareprograms, computer hardware and robot connections of a robot controlsystem according to the present invention;

[0033]FIG. 2 is simplified flowchart of a preferred embodiment ofsoftware and method steps for providing a watchdog intercommunicationbetween the general purpose computer and the real-time computersubsystem;

[0034]FIG. 3 is a side elevation view of an articulating industrialrobot illustrating another type of robot configuration controllable byembodiments of the present invention;

[0035]FIG. 4 is a side elevation view of an industrial robot equippedwith linear joints and illustrating one of the many types of robotconfigurations controllable by embodiments of the present invention;

[0036]FIG. 5 is a simplified flow chart of preferred software and methodsteps for accommodating robots of different electromechanicalconfigurations and demonstrating the role of the configuration variablein control systems according to the present invention;

[0037]FIG. 6 is likewise an exemplary operator interface display screengenerated in response to data stored in the configuration variablespecifying a rotational joint configuration;

[0038]FIG. 7 is an exemplary operator interface display screen generatedin response to data stored in the configuration variable specifying alinear joint;

[0039]FIG. 8 is schematic block diagram illustrating the softwareprograms, computer hardware and equipment connections of an automationequipment control system according to the present invention applied to alaboratory liquid-handling system;

[0040]FIG. 9 is schematic block diagram illustrating a control systemaccording to the present invention applied to simultaneously control twodifferent automation equipment centers; and

[0041]FIG. 10 is a schematic block diagram showing features of thewatchdog intercommunication applied to multiple processes in the generalpurpose computer.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0042] The invention disclosed herein is, of course, susceptible ofembodiment in may different forms. Shown in the drawings and describedherein below in detail are preferred embodiments of the invention. It isto be understood, however, that the present disclosure is anexemplification of the principles of the invention and do not limit theinvention to the illustrated embodiments.

[0043] In the FIGURES, a single block or cell may indicate severalindividual software and/or hardware components that collectively performthe identified single function. Likewise, a single line may representseveral individual signals or several instances of software data sharingor interconnection.

[0044] Robots as well as other manufacturing machines includepositioning arms with mechanical joints, positioning actuators such asmotors for causing movement about the joints, and position feedbacksensors which provide an indication of the position of some part of therobot. Automation equipment other than robots generally also includepositioning actuators to cause movement about joints, and feedbacksensors to provide an indication of the position of parts of theautomation equipment.

[0045] As used herein, the term “automation equipment” is a reference tothe variety of devices used to automate otherwise manual tasks andhaving mechanical joints for defined motion and mechanical actuators forpowering movement about the mechanical joints. Exemplary automationequipment includes industrial robots, laboratory robots, machine tools,parts handlers, laboratory liquid-handling systems, computer medialoading systems, therapeutic systems, surgical systems, and the like.

[0046] As used herein, the term “mechanical actuator” is a reference tothe variety of devices used for robot motion. Exemplary robot actuatorsare hydraulic pistons, pneumatic pistons, servo motors, stepper motorsand linear motors.

[0047] As used herein, the term “mechanical actuator” also refers to thevariety of devices used to move the joints of automation equipment (ordevices). Hydraulic pistons, pneumatic pistons, servo motors, steppermotors and linear motors are equally exemplary of actuators used for thevarious types of automation equipment other than robots.

[0048] Referring to FIG. 1, the elements of a control system 10 areshown with an industrial robot 4, a Cincinnati Milacron 776 robot. Robot4 includes a series of revolute joints 5, 6, 7 and 8, correspondingservo motors, and an end effector 9. Control system 10 includes ageneral purpose computer 14 and a real-time computer subsystem 16.

[0049] The phrase “general purpose computer,” as used herein, refers tocommercially available standard computers which are designed formultiple applications as opposed to CPU-based electronics customized fora specific application such as device control. Examples include thewell-known group of computers conventionally labeled IBM-compatiblepersonal computers, or more simply PCs. PCs are based on complexinstruction set (CISC) CPUs from Intel Corporation (INTEL), AdvancedMicro Devices, Inc. (AMD), VIA Technologies, Inc, and the like. Therelated, evolving CPU product line from INTEL includes CPU chip setsavailable under the designations “80486®,” “Pentium®,” “Pentium® II,”“Pentium® III.” An exemplary CPU product line for general purposecomputers by AMD is available under the designation “AMD-K6®.” VIATechnologies, Inc. CPUs for general purpose computers are sold under thedesignation “Cyrix®.”

[0050] General purpose computers based on reduced instruction set (RISC)CPUs are also well known. Examples include computers based on the Alpha®chip set available from the Compaq Computer Corporation.

[0051] As indicated in FIG. 1, general purpose computer 14 operates witha general purpose operating system. The phrase “general purposeoperating system” is a reference to commercially standard operatingsystems such as those available from the Microsoft Corp. under thedesignations MS-DOS®, Windows 95®, Windows 98®, Windows NT®, Windows2000®, Windows XP®. Other examples of general purpose operating systemsinclude Macintosh® (Apple Computers, Inc.), UNIX (various resellers),Open VMS® (Compaq Computer Corporation), and the like. The generalpurpose operating system is preferably a member of the group consistingof a Windows XP®, a Windows-NT®, a Windows 2000®, a Windows 95®, aWindows 98®, an Open VMS®, a PC/MS DOS, and a Unix.

[0052] Installed for running on the general purpose computer are aprogram execution module 18, an operator interface module 20, andwatchdog communication code segments 22. The term “module,” as usedherein refers to a software element such as a program, subprogram,software process, subroutine, or grouping of code segments and the like.The software modules of control system 10 are preferably discreteexecutable programs which run as discrete processes. Unless otherwiseindicated, the software modules and code segments are configured toshare access to a variety of software variables and constants as neededthrough subroutine calls, common shared memory space, and the like.

[0053] Program execution module 18 processes programs of robotinstructions 24, which can be stored as data files as represented inFIG. 1. From robot instruction programs 24, program execution module 18generates robot move commands 26 for delivery to real-time computersubsystem 16. Via execution module 18, the relatively more humanreadable robot instructions 24 generated by a robot operator areinterpreted and translated into move commands 26 for real-time computersubsystem 16.

[0054] As well, program execution module 18 allows operator control ofthe running of robot programs 24 by selectively starting and stoppingthe transfer of move commands 26 to real-time computer subsystem 16 inresponse to prompts from the operator via operator interface module 20.

[0055] Operator interface module 20 is operably linked to an operatordisplay screen 28, a keyboard and/or mouse 30, and other standardperipherals as desired. In a preferred embodiment, display screen 28 isa touch screen which allows a robot operator to input prompts and datathrough both displays and keyboard/mouse 30.

[0056] With robot operator prompts and selections, operator interfacemodule 20 allows robot instruction files 24 to be loaded from disk andprocessed (or executed) by program execution module 18 for controllablymoving robot 4. Operator interface module 20 generates operator screensand accepts from the operator numeric data and prompts. Numeric dataentries are communicated to other program modules as necessary. Promptsby the robot operator to start and stop the running of a robot programare received by operator interface module 20 and forwarded to executionmodule 18.

[0057] In addition to accepting operator inputs for loading, startingand stopping programs 24, operator interface 20 preferably includes aneditor for use by an operator to generate new programs of robotinstructions 25. Because the present invention provides a control systemwhich relies upon general purpose computers such as a Windows NT PC, itis equally possible to generate robot programs on another PC such as anoffice PC and then transfer the file to general purpose computer 14through standard peripherals such as disk drives or computer networkconnections.

[0058] General purpose computer 14 is electronically linked for dataexchange (i.e. communication) with real-time computer subsystem 16.Realtime computer subsystem 16 preferably includes a hardware, firmwareand software combination designed for process control applications. Asopposed to general purpose computers with general purpose operatingsystems, real-time computers provide for substantially uninterruptibleexecution of calculations required for a plurality of control loops withrelatively fast cycle times (e.g. 0.5-2 msec).

[0059] Because of the extensive signal processing requirements, the CPUcomputer of real-time computer subsystem 16 is preferably a DSP-basedcomputer. In this category of DSP-based control computers, the systemscommercially available from Delta Tau Data Systems, Inc. (Chatsworth,Calif.) under the designations “PMAC”, “PMAC2,” “Turbo PMAC” and “UMAC”are presently preferred.

[0060] Real-time computer subsystem 16 includes a robot move module 32,a move command data buffer 34, kinematic models 36, servo controlalgorithms 38, and watchdog intercommunication code segments 40.Real-time subsystem 16 also includes I/O hardware and software driversto provide an operable link to the positioning related electronics ofrobot 4. Represented by block 42 in FIG. 1 are the hardware and softwarecomponents necessary for receiving and translating robot feedbacksignals 44 into computer data feedback signals 46. Likewise, block 48represents the components necessary for converting computer datasetpoints 50 into actuator-appropriate activation signals 52.

[0061] Activation signals 52 and feedback signals 44 may be analogsignals, digital signals or combinations of both depending upon theconfiguration of robot 4. For example, the typical motor-with-amplifieractuator calls for an analog activation signal. Newer, so-called “smart”devices can be directly activated by digital signals, however. Thus, thetype of signal conversion performed by I/O systems 42 and 48 varies byrobot configuration.

[0062] Robot move module 32 is resident in real-time computer subsystem16 to accept move commands 26 and feedback signals 44/46 to generate thenecessary activation signals 50/52. Robot move module 32 relies uponkinematic models 36 and servo control algorithms 38 to translate movecommands 26 into required joint positions and then appropriateactivation signal setpoints 50. In a preferred embodiment of the presentinvention, move commands 26 are expressed as changes in joint positionor as changes in end-effector position.

[0063] Move commands based on joint position rely upon a predefinedrange on a one-dimensional joint axis model, for example, +90 degrees to−90 degrees for a revolute axis and 0 to 1200 millimeters (mm) for alinear joint. An example of a move command based on joint position is“set joint one at 60 degrees.” In a preferred embodiment of the presentinvention, robot move module 32 is programmed to accept joint movecommands as a function call specifying the position of all robotmechanical joints 5, 6, 7 and 8, thereby allowing only one or all jointsto be moved, as desired.

[0064] Move commands expressed as end-effector positions rely upon apredefined, but customary, three-dimensional coordinate system forlocating the end-effector. A move command based on end-effector positionis a call to move the end effector to a point in the end-effector'sworkspace.

[0065] For joint position move commands, robot move module 32 includessoftware models for translating data from feedback signals 46 into jointposition. The required calculation varies according to joint type andthe type feedback signal available. For example, a feedback sensordirectly measuring an indication of joint position requires limitedtranslation, while a feedback sensor measuring the number of rotationsof a positioning motor may require a more complex translation.

[0066] To process move commands based on end-effector position, robotmove module 32 additionally includes a kinematic model for calculatingthe required position of joints 5, 6, 7 and 8, given a desired positionfor end effector 9.

[0067] More specifically, real-time computer subsystem 16 uses kinematicmodel algorithms for computation of the forward and inverse kinematicsof the robot. Forward kinematics computation refers to the determinationof end-effector position and orientation given known joint positions oractuator positions of the robot. Inverse kinematics is the determinationof the joint angle or actuator positions given an end-effector position.

[0068] The required combination of individual joint axes models andoverall kinematics models is represented in FIG. 1 by block 36.

[0069] Kinematic algorithms are described in other patents and thetechnical literature. See, for example, Chapters 3 and 4 of Craig, JohnJ. Introduction to Robotics: Mechanics and Control, 2nd Ed.,Addison-Wesley, 1989. The specific models employed vary according to theelectromechanical configuration of the robot to be controlled.

[0070] Because the positioning actuator and feedback sensor combinationmake up a dynamic system, real-time computer subsystem 16 also includescontrol algorithms 38 to provide the required dynamic calculations.Preferred among available closed loop servo motor control schemes is aproportional-integral-derivative (PID) with feedforward algorithm.

[0071] Data buffer 34 is a software variable available to programs inboth general purpose computer 14 and real-time computer subsystem 16 forstoring multiple move commands 26 received from program execution module18. Although the desired storage capacity for data buffer 34 can vary,in a preferred embodiment of the present invention data buffer 34 andconnected modules are preferably configured such that from 2 to 10, andmore preferably from 3 to 4, move commands are stored.

[0072] With move command data buffer 34, control system 10 provides forsubstantially continuous, uninterrupted control of robot 4 even inresponse to program execution delays in general purpose computer 14.

[0073] As noted above, general purpose computers running general purposeoperating systems are relatively unreliable, exhibiting unpredictablecontrol program interruption. Specific motion control of robot 4 byreal-time computer subsystem 16 is not affected by unpredictable delaysin operations of general purpose computer 14 because robot move module32 can continue to draw move commands 26 from data buffer 34.

[0074] Although a variety of data transfer mechanisms are available toprovide electronic and software-level communication between generalpurpose computer 14 and real-time computer subsystem 16, a commerciallystandard data bus backplane is preferred. The data bus connection issymbolically represented in FIG. 1 by reference numeral 54. Suitabledata bus standards can be selected from the group consisting of an ISAbus, a PCI bus, a VME bus, a universal-serial-bus (USB), an Ethernetconnection, and the like. The ISA bus, the PCI bus, and the VME bus areexemplary standard data buses, with the ISA bus being presentlypreferred.

[0075] For convenient space-saving connection to data bus 54, thecomputer mother board portions of general purpose computer 14 andreal-time computer subsystem 16 are data bus cards. As used herein, theterm “bus card” is a reference to printed circuit boards with electroniccomponents and a tab with a plurality of contacts that is received inthe card slots of a data bus chassis. The DSP real-time computersavailable from Delta Tau Data Systems, Inc. noted above are available asISA data bus cards.

[0076] In a preferred embodiment, control system 10 includes a security(or “watchdog”) communication (blocks 22 and 40) between general purposecomputer 14 and real-time computer subsystem 16. Flowchart FIG. 2 showsthe preferred code segments for maintaining the watchdog management. Asillustrated, a preferred watchdog scheme includes code segmentsoperating in both general purpose computer 14 and real-time computersubsystem 16. Resident in general purpose computer 14 is a status codesegment 56 and resident in the real-time computer subsystem are a timercode segment 58, a timer reset code segment 60, and a fail safe codesegment 62.

[0077] The code segments interact with two software variables: anactivity software switch (ASW) 64 for indicating whether programs ingeneral purpose computer 14 are active and/or error free, and a timervariable (TV) 66 for storing an elapsed time indication. Timer variable66 is resident in real-time computer subsystem 16 while activitysoftware switch (ASW) 64 is shared via data bus 54 or other means.Activity software switch 64 is implemented as an integer softwarevariable with an unset position being represented by zero and a set, oractive position, being represented by one.

[0078] Status code segment 56 optionally, but preferably, runssequentially with program execution module 18 (box 68) and repeatedlysets activity software switch 64 to the active position (box 74). Afterthe completion of a run cycle of program execution module 18, statuscode segment 56 examines other software variables which indicate specialerrors (box 70) or delays in the processing of other programs (box 72)in the general purpose computer 14. Accordingly, if program executionmodule 18 is interrupted or if errors or other delays are detected,activity switch 64 is not set.

[0079] Timer code segment 58 counts down timer variable 66 according toelapsing time. Timer code segment 58 is preferably a system servicefunction of real-time computer subsystem 16 and expressed in executioncycles.

[0080] When the activity software switch is in the active position (box76), timer reset code segment 60 repeatedly resets the timer variable toa predetermined amount of time (box 78; preferably two seconds) andrepeatedly sets the activity software switch back to the unset position(box 80). Fail safe code segment 62 responds to an overrun of timervariable 66 (box 82) by shutting down robot 4 via activation signals50/52 and other robot I/O.

[0081] Acting together, code segments 56, 58, 60 and 62, provide awatchdog service which will shut down robot 4 if the operation ofgeneral purpose computer 14 is stopped or delayed for more than twoseconds.

[0082] Referring back to FIG. 1, another feature of the presentinvention is that the software provided for general purpose computer 14is suitable for controlling robots of various electromechanicalconfigurations. According to this aspect of the invention, generalpurpose computer 14 serves as a robot-independent computer unit whilereal-time computer subsystem 16 serves as a somewhat robot-specificcontroller unit, or customized interface or adapter to the robot.

[0083] Important to the multi-configuration aspect of the presentinvention is the enhanced versatility of operator interface module 20.Viewed together, FIGS. 3 and 4 demonstrate the challenge of working withrobots of different electromechanical configurations. FIG. 3 is sideview of articulating robot 4 from FIG. 1 in slightly larger scale toreveal greater detail. The arms of robot 4 are connected by a series ofrevolute (or rotary) joints 5, 6, 7 and 8. In contrast, FIG. 4 is sideview of a robot 86 which is equipped with a revolute, torso joint 87 andtwo linear joints 88 and 89.

[0084] Assigning joint numbers from the base up, the second and thirdjoints of robot 4 are of a different type than the second and thirdjoints of robot 86. To overcome this difference in configuration, theoperator interface of the present invention includes a configurationvariable for storing data specifying the electromechanical configurationof the robot and display generating code segments for each type ofconfiguration.

[0085] In a preferred embodiment, the configuration variable is definedand/or sized to store data defining the type of robot joint, linear orrevolute, and whether a specified revolute joint is windable, i.e.capable of turning more than 360 degrees.

[0086]FIGS. 5 through 7 provide an example of how operator interfacemodule 20 (FIG. 1) uses the configuration variable to accommodatedifferent types of robots. As illustrated in FIG. 5, a display selectingcode segment 90 responds to an operator request to set limits forjoint/axis 3 (box 92). Code segment 90 checks in configuration variable94 for data specifying whether joint 3 is linear or revolute (box 96).

[0087] Depending upon whether the third joint of the robot to becontrolled is revolute as with robot 4 or linear as with robot 86, codesegment 90 selects one of two available displays for setting jointlimits. For a revolute joint type, box 98 is selected and the revolutejoint/axis display of FIG. 6 is generated at screen 28. For a linearjoint type, box 100 is selected and the linear joint/axis display ofFIG. 7 is generated.

[0088] Operator interface module 20 is one example of the many softwareprocesses installed on general purpose computer 14 that preferably relyon settings in an electromechanical configuration variable (i.e. dataset) to provide adaptability. An exemplary configuration variable isdefined to store specifications for the number of mechanical jointspresent on the robot or other automation equipment to be controlled, thetype for each joint (e.g. linear), the distance between respectivemechanical joints and the range of motion for each joint.

[0089]FIG. 8 illustrates a control system 110 according to the presentinvention applied to laboratory automation equipment, and morespecifically, a laboratory liquid handling system 104. Liquid handlingsystem 6 has three linear mechanical joints 105, 106 and 107,corresponding servo motors and a pipette end effector 109. End effector109 preferably includes an optical detector in the form of a digitalcamera for providing control system 110 an alignment indicator.

[0090] Control system 110 includes a general purpose computer 114 and areal-time computer subsystem 116. Installed on the general purposecomputer are a program execution module 118, an operator interfacemodule 120, and watchdog communication code segments 122.

[0091] Program execution module 118 is a software process adapted toprocesses automation equipment instructions 124. As noted above inreference to robot control system 10 (FIG. 1), the instructions 124 arepreferably stored as data disk files on general purpose computer 114 oron compatible removable storage media. From equipment instructionprograms 124, program execution module 118 generates move commands 126for delivery to real-time computer subsystem 116.

[0092] Equipment instructions 124 preferably take the form of operatorreadable text or flow-chart source code. Execution module 118 translatesequipment instructions 124 into move commands 126. Via operatorinterface module 120, program execution module 118 allows equipmentoperators to start and stop the transfer of move commands 126 toreal-time computer subsystem 116.

[0093] Operator interface module 120 is operably linked to an operatordisplay screen 128, a keyboard and/or mouse 130, and other standardperipherals as desired. Interface module 120 includes code segments tocreate operator screens and accept operator inputs. Interface module 120allows robot instruction files 124 to be loaded from disk and processedby program execution module 118 for controllably moving liquid handlingsystem 104.

[0094] In addition to accepting operator inputs for the loading,starting and stopping of programs 124, operator interface 120 includes afile editor for use by an operator to generate new instruction files125.

[0095] General purpose computer 114 is electronically interconnected fordata communication with real-time computer subsystem 116 via one of avariety of a standard data buses 154 as described above in reference tocontrol system 10. A preferred real-time computer for providingsubsystem 116 is commercially available from Galil Motion Control(Rocklin, Calif.) under the designation “DMC-18x2.” The DMC-18x2real-time computers rely on a PCI bus connection to general computer114.

[0096] Real-time computer subsystem 116 includes a move module 132, amove command data buffer 134, kinematic models 136, servo controlalgorithms 138, and watchdog intercommunication code segments 140.Subsystem 116 also includes I/O hardware and software drivers to providean operable link to the positioning related electronics of liquidhandling system 104. Represented by block 142 are the hardware andsoftware components necessary for receiving and translating liquidhandling system feedback signals 144 into computer data feedback signals146. Block 148 represents the components necessary for convertingcomputer data setpoints 150 into actuator-appropriate activation signals152.

[0097] Laboratory liquid handling system 104 is equipped with a pipetteend effector 109 including control valves, a peristalic pump andoptionally a flow rate sensor. Block 149 represents the hardware andsoftware interface components for accessing these end effector elements.

[0098] Move module 132 accepts move commands 126 and feedback signals144/146 to generate the necessary activation signals 150/152. Movemodule 132 relies upon kinematic models 136 to translate move commands126 into required joint positions and then appropriate activation signalsetpoints 150. Move commands 126 may be specified as changes in jointposition or as changes in end-effector position.

[0099] For example, to process move commands based on the position ofpipette 109, move module 132 includes a kinematic model for calculatingthe required position of joints 105, 106 and 109.

[0100] Data buffer 134 is a software variable available to programs inboth general purpose computer 114 and real-time computer subsystem 116for storing multiple move commands 126 generated by program executionmodule 118. Data buffer 134 preferably includes capacity to store from 2to 10, and more preferably from 3 to 4, move commands.

[0101] Also contemplated for the present control systems is the operatordirection of multiple automation devices via a single general-purposecomputer. Referring now to FIG. 9, system 210 simultaneously controlsboth an industrial robot 204A and a multi-axis milling machine tool204B.

[0102] As described above in reference to robot 4 and control system 10(FIG. 1), robot 204A is a Cincinnati Milacron 776 robot having a seriesof revolute mechanical joints, corresponding servo motors and an endeffector 209A. Milling machine tool 204B is equipped with a series oforthogonally disposed linear mechanical joints with conventionalactuators and a cutting tool end effector 209B.

[0103] Each automation device 204A and 204B is served by separatereal-time computer subsystems 216A and 216B, respectively. Real-timesubsystem 216A is customized for control of robot 204A. Subsystem 216Aincludes hardware and software interface components 248A to transferactivation signal setpoints 250A to robot 204A actuators, interfacecomponents 242A to receive and translate position feedback signals 244Aand interface components 245A for communication with end effector 209A.Also installed on real-time subsystem 216A is a move command data buffer234A for receiving move commands 226A from general purpose computer 214,a move module software process 232A for translating move commands intoactivation signal setpoints 250A and watchdog communication codesegments 240A to shutdown robot 204A in the event of a fault in generalpurpose computer 214.

[0104] Subsystem 216B is customized for control of the relatively lesscomplex milling center 204B. Subsystem 216B includes software andhardware components corresponding to those identified for subsystem216A, namely, a move data buffer 234B for storing move commands 226B, amove module 232B for processing move commands 226B into activationsignal setpoints 250B, watchdog code segments 240B, interface components248B for generating activation signals 252B, interface components 245Bfor directing end effector 209B and interface components 242B fortranslating feedback signals 244B into digital software data 246B.

[0105] It is a feature of the present invention that the interfacehardware (e.g. 245A/B and 248A/B) and the software modules making up thereal-time subsystems can be customized according to the selectedautomation equipment to be controlled, while the software modulesresident on the general purpose computer (e.g. operator interface 220)can accommodate differing automation devices and their relatedelectromechanical configurations. For example, industrial robot 204A hasat least four revolute mechanical joints and corresponding actuators,while machining center 204B has a lower number of linear joints.Therefore, milling center subsystem 216B is customized with relativelyless complex interface connections, than the connections required bysubsystem 216A for robot 204A. Furthermore, the kinematic model presentin move module 232B of subsystem 216B for machining center 204B can berelatively less complex than those kinematic models present in movemodule 232A of subsystem 216A.

[0106] General purpose computer 214 of control system 210 has anoperator interface 220 linked to a display 228 and peripherals 230, andseparate execution modules 218A and 218B for each automation devicesubsystem. Operator interface module 220 generates operator screens andaccepts from the operator, prompts and data.

[0107] Operator interface module 220 allows the creation and loading ofequipment instruction programs, which are represented in FIG. 9 withreference numerals 224A, 224B and 224C. More specifically, 224Arepresents files with instructions solely for robot 204A, 224Brepresents files with instructions solely for milling center 204B, 204Crepresents files containing instructions for both robot 204A and millingcenter 204B.

[0108]FIG. 9 represents a single operator interface module 220 fordirecting the activities of both automation devices, robot 204A andmilling center 204B. In an alternate embodiment, general purposecomputer 214 includes a separate operator interface module for eachautomation device.

[0109] Execution module 218A processes programs of instructions forrobot 204A and stores corresponding move commands 226A in data buffer234A. Execution module 218B translates instruction programs 224 formilling center 204B storing resulting move commands 226B to data buffer234B.

[0110] In an alternate embodiment, control system 210 relies on a singleexecution module to translate instructions for multiple automationdevices and selectively forward move commands 226A or 226B to theappropriate subsystem.

[0111] Although represented in FIG. 9 as two separate blocks 222A and222B, the watch dog intercommunication function between general purposecomputer 214 and each real-time subsystem 216A and 216B preferablyrelies on the same operating code segments. The watchdog code segmentsin general purpose computer 214 set separate activity software switchesfor each subsystem 216A and 216B. If one or more critical softwareprocesses fail to execute, neither the activity software switch forsubsystem 216A nor the activity software switch for subsystem 216B willbe set to active. As described above in reference to FIG. 2, if theactivity software switches are not set to active in a timely manner, thewatchdog code segments 240A and 240B operating in each real-timesubsystem will shut down their respective automation devices.

[0112] A key feature of the present invention is the watchdogintercommunication between the general purpose computer and thereal-time computer subsystem. FIG. 10 illustrates a preferred embodimentof the watchdog intercommunication feature applied individually tomultiple software processes of control system 10.

[0113] Control system 10 includes multiple software processes, some ofwhich are critical to the control function such as execution module 18and operator interface 20. According to a preferred approach to thewatchdog feature, control system 10 includes an activity software switchfor each critical process. For example, execution module 18 has anactivity software switch 19 (ASW1) and operator interface module 20 hasan activity software switch 21 (ASW2). A separate high-priority, statusreview process 27 polls the plurality of activity software switches,ASW1 . . . ASWn, and sets a main activity software switch 64 (ASW) onlyif all of the individual process activity switches are active.

[0114] Each critical software process has code segments for setting theassigned activity software switch to active. For example, executionmodule 18 includes code segment 31. This activity code segment ispreferably at the end of the execution sequence. If a critical processfails to fully execute, the activity software switch is not set andsubsystem 16 fails safe to shutdown robot 4.

[0115] Timer reset code segment 60 in real-time subsystem 16 continuallyresets timer variable 66 when main software activity switch 64 is set tothe active position. A system-service timer code segment 58 (FIG. 2)continually increments timer variable 66 according to elapsed time.Timer variable 66 therefore serves as a measure of elapsed time sincesoftware processes of general purpose computer reported activity. Failsafe code segment 62 monitors timer variable 66 and shuts down robot 4if the elapsed time of inactivity exceeds a predetermined safety limit.

[0116] The foregoing specification and drawings are to be taken asillustrative but not limiting of the present invention. Still otherconfigurations and embodiments utilizing the spirit and scope of thepresent invention are possible, and will readily present themselves tothose skilled in the art.

We claim:
 1. A control system for processing a program of instructionsfor automation equipment having a mechanical joint, a mechanicalactuator to move the joint and a position feedback sensor, themechanical actuator being adapted to receive an activation signal andthe feedback sensor providing a position signal, the control systemcomprising: a general purpose computer with a general purpose operatingsystem, said general purpose computer including a program executionmodule to selectively start and stop processing of the program ofinstructions and to generate a plurality of move commands; and areal-time computer subsystem in electronic communication with saidgeneral purpose computer and operably linked to the mechanical actuatorand the position feedback sensor, said real-time computer subsystemincluding a move command data buffer for storing said plurality of movecommands, a move module linked to said data buffer to sequentiallyprocess said plurality of move commands and calculate a requiredposition for the mechanical joint.
 2. The control system according toclaim 1 wherein said realtime computer subsystem also includes a controlalgorithm in software communication with said move module to repeatedlycalculate a required activation signal from the feedback signal and saidrequired position for the mechanical joint.
 3. The control systemaccording to claim 1 wherein the mechanical actuator is a servo motorand said control algorithm is a servo control algorithm.
 4. The controlsystem according to claim 1 wherein the position feedback sensor is anoptical detector.
 5. The control system according to claim 1 whereinsaid optical detector is a digital camera.
 6. The control systemaccording to claim 1 further comprising a watchdog intercommunicationbetween said real-time computer subsystem and said general purposecomputer for detecting faults in the operation of said general purposecomputer.
 7. The control system according to claim 1 wherein saidgeneral purpose operating system is not tied to real-time.
 8. Thecontrol system according to claim 1 wherein said general purposeoperating system is a member of the group consisting of a Windows XP®, aWindows-NT®, a Windows 2000®, a Windows 95®, a Windows 98®, an OpenVMS®, a PC/MS DOS, and a Unix.
 9. A control system suitable forcontrolling automation equipment of different electromechanicalconfigurations, the control system comprising: an equipment-independentcomputer unit including a video display and a first digital processoradapted to run an operator interface module for creating a move command;and an equipment-specific controller unit operably linked to theautomation equipment including a move module for executing said movecommand, said equipment-specific controller unit being in electroniccommunication with said equipment-independent computer unit.
 10. Thecontrol system according claim 9 wherein said equipment-specificcontroller unit includes a second digital processor adapted to run areal-time tied operating system.
 11. The control system according toclaim 9 wherein said general-purpose computer and said real-timecomputer subsystem are electronically linked via a standard data bus.12. The control system according to claim 9 wherein said general-purposecomputer and said real-time computer subsystem are electronically linkedvia a data bus selected from the group consisting of an ISA bus, a PCIbus, a VME bus, a universal-serial-bus (USB) and an Ethernet connection.13. The control system according to claim 9 further comprising: aconfiguration variable for storing data specifying the electromechanicalconfiguration of the automation equipment; a first code segment forgenerating a first operator display according to a firstelectromechanical configuration; a second code segment for generating asecond operator display according to a second electromechanicalconfiguration; and a third code segment for selecting said first orsecond code segment according to said electromechanical configuration.14. The control system of claim 13 wherein said configuration variableis defined to store data specifying the distance between two mechanicaljoints present on the automation equipment.
 15. The control system ofclaim 13 wherein said configuration variable is defined to store dataspecifying the number of mechanical joints of the automation equipment.16. An operator interface module for controlling automation equipment ofdifferent electromechanical configurations, the operator interfacemodule comprising: a first code segment for generating a first operatordisplay according to a first electromechanical configuration; a secondcode segment for generating a second operator display according to asecond electromechanical configuration; and a third segment forselecting said first or second code segment according to saidelectromechanical configuration.
 17. The operator interface according toclaim 16 wherein said second code segment generates an operator displayrequesting operating limits for a linear joint.
 18. The operatorinterface module of claim 16 wherein said configuration variable isdefined to store data specifying a mechanical joint type.
 19. A controlsystem suitable for controlling a plurality of automation devices, eachdevice having a mechanical joint and a mechanical actuator to move thejoint, the control system comprising: a general purpose computer with ageneral purpose operating system, the general purpose computer includinga video display and a first digital processor adapted to run an operatorinterface module; and a plurality of real-time computer subsystems eachin electronic communication with said general purpose computer and eachoperably linked to one of said automation devices, each subsystemincluding a digital processor adapted to run a real-time tied operatingsystem and a move module for executing move commands.
 20. The controlsystem of claim 19 adapted to control an industrial robot and a machinetool.
 21. The control system according to claim 19 further comprising awatchdog intercommunication between at least one of said plurality ofreal-time computer subsystems and said general purpose computer fordetecting faults in operation of said general purpose computer.
 22. Thecontrol system according to claim 19 wherein at least one of saidplurality of subsystems includes a move command data buffer for storingsaid plurality of move commands, a move module linked to said databuffer to sequentially process said plurality of move commands andcalculate a target position for the mechanical joint, and a controlalgorithm in software communication with said move module to calculate arequired activation signal from said target position for the mechanicaljoint.
 23. An automated manipulation system for executing a program ofinstructions, the system comprising: a manipulator having a mechanicaljoint, an actuator to move said joint and a position sensor, saidactuator being adapted to receive an activation signal and said positionsensor providing a position signal, a general purpose computer with ageneral purpose operating system, said general purpose computerincluding a program execution module to selectively start and stopprocessing of the program of instructions and to generate a plurality ofmove commands; and a real-time computer subsystem in electroniccommunication with said general purpose computer and operably linked tothe mechanical actuator and the position sensor, the real-time computersubsystem including a move command data buffer for storing saidplurality of move commands, a move module linked to said data buffer tosequentially process said plurality of move commands and calculate arequired position for the mechanical joint.
 24. The system according toclaim 23 wherein the manipulator is a laboratory automation device. 25.The system according to claim 24 wherein the laboratory automationdevice is a liquid handling system.
 26. The system according to claim 23wherein the manipulator is an articulating industrial robot.
 27. Acontrol system for automation equipment having a mechanical joint, amechanical actuator to move the joint, the mechanical actuator beingadapted to receive an activation signal, the control system comprising:a general purpose computer with a general purpose operating system forproviding an operator interface, said general purpose computer includinga plurality of software processes; a real-time computer subsystem inelectronic communication with said general purpose computer and operablylinked to the mechanical actuator, the real-time computer subsystemincluding a code segment algorithm for resetting said activation signal;and a watchdog intercommunication between said real-time computersubsystem and said general purpose computer for detecting faults inoperation of said general purpose computer.
 28. A control system forautomation equipment having a mechanical joint, a mechanical actuator tomove the joint, the mechanical actuator being adapted to receive anactivation signal, the control system comprising: a general purposecomputer with a general purpose operating system for providing anoperator interface, said general purpose computer including a pluralityof software processes; a real-time computer subsystem in electroniccommunication with said general purpose computer and operably linked tothe mechanical actuator; and a watchdog intercommunication between saidreal-time computer subsystem and at least two of said plurality ofsoftware processes for detecting interruption of the execution of saidsoftware processes.
 29. The control system according to claim 28 whereinsaid watchdog intercommunication includes: a plurality of activitysoftware switches each having an active position and an unset position;a status code segment in each of said plurality of software process forrepeatedly setting a predetermined one of said activity softwareswitches to said active position; a timer variable for storing anelapsed time indication; a timer code segment for adjusting said timervariable according to passing time; a timer reset code segment installedin said real-time computer subsystem for repeatedly resetting said timervariable to a predetermined amount of time when all of said plurality ofactivity software switches are in said active position and repeatedlyresetting said plurality of activity software switches to said unsetposition; and a fail safe code segment installed in said real-timecomputer subsystem for repeatedly inspecting said timer variable andsetting said activation signal to shut down the robot if said timervariable reaches a predetermined value.
 30. A control system forprocessing a program of robot instructions for robots having amechanical joint, a mechanical actuator to move the joint and a positionfeedback sensor, the control system comprising: a general purposecomputer with a general purpose operating system, said general purposecomputer including a program execution module to selectively start andstop processing of the program of robot instructions and to generate aplurality of robot move commands; and a real-time computer subsystem inelectronic communication with said general purpose computer and operablylinked to the mechanical actuator and the position feedback sensor, thereal-time computer subsystem including a move command data buffer forstoring said plurality of move commands, a robot move module linked tosaid data buffer to sequentially process said plurality of move commandsand calculate a required position for the mechanical joint.
 31. Thecontrol system according to claim 30 wherein the position feedbacksensor is an optical detector.
 32. The control system according to claim30 wherein said optical detector is a digital camera.
 33. A controlsystem for processing a program of robot instructions for robots havinga mechanical joint, a mechanical actuator to move the joint and aposition feedback sensor, the control system comprising: a generalpurpose computer with a general purpose operating system, said generalpurpose computer including a program execution module to selectivelystart and stop processing of the program of robot instructions; and areal-time computer subsystem in electronic communication with saidgeneral purpose computer and operably linked to the mechanical actuatorand the position feedback sensor, the real-time computer subsystemincluding a move module to calculate required positions for themechanical joint.
 34. The control system according to claim 33 furthercomprising a watchdog intercommunication between said real-time computersubsystem and said general purpose computer for detecting faults inoperation of said general purpose computer.